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Job Description
Role
As a CFD Engineer – Propulsion and Battery Systems, you will lead DFMEA-driven 3D
Computational Fluid Dynamics (CFD) analysis at the component, subsystem, and
system level to optimize thermal performance and system reliability across GM propulsion
systems. Operating within a DFMEA-centric environment, you will use virtual engineering
to identify failure modes, evaluate severity/occurrence risks, and drive robust risk
mitigation strategies for propulsion systems, specifically battery and power electronics
thermal performance, durability and safety requirements.
Work Arrangement
Hybrid work position: This position does not require an employee to be on-site full-time to
perform most effectively. The employee’s role enables them to work at a GM facility or off-
site as frequently as needed or desired.
Primary Responsibilities
● Perform DFMEA-aligned 3D CFD analysis focusing on high-voltage battery systems
and power electronics to identify and mitigate critical thermal failure modes at the
cell, module, pack, and system level.
● Simulate and quantify battery Thermal Runaway Propagation (TRP), venting gas
dynamics, and safety physics under severe abuse scenarios to validate DFMEA
mitigation designs, barrier integrity, and failure containment controls.
● Lead thermal risk assessments during early architecture definition and concept
selection using rapid CFD trade studies to eliminate high-risk failure modes prior to
design freeze.
● Correlate virtual failure mode predictions with physical test and validation data to
ensure simulation fidelity in predicting real-world failure thresholds and reliability
margins.
● Clearly and effectively communicate analysis plans, assumptions, and results to
internal and external stakeholders using presentations, reports, and design reviews.
● Meet or exceed timing, quality, and cost targets within structured product
development processes.
● Participate in and/or lead benchmarking and advanced methods activities to
continuously improve GM’s virtual engineering capabilities in CFD and multi-
physics analysis.
Required Skills and Experience
● 5+ years of experience with simulation, design, testing, or release of propulsion-
related systems (e.g., engines, transmissions, e-drive units, batteries, power
electronics, thermal management systems).
● Hands-on experience with at least one commercial 3D CFD software package
(e.g., STAR-CCM+, Simerics-MP+, Fluent, or equivalent).
● Demonstrated understanding of heat transfer and fluid mechanics (conduction,
convection, radiation, pressure loss, turbulence, etc.) applied to real engineering
systems.
● Familiarity or practical experience with vehicle propulsion system design,
operation, or testing.
● BS in Mechanical or Aerospace Engineering (or closely related field) required.
Preferred Skills and Experience
● 5+ years of advanced experience with 3D CFD thermal and fluid analysis
specialized for battery pack and module systems.
● Experience in modeling battery Thermal Runaway Propagation (TRP) and gas
venting dynamics under severe thermal abuse and cell failure conditions.
● Experience with electro-thermal multi-physics coupling, integrating
electrochemical heat generation models with 3D CFD for cell characterization,
module, and pack simulations.
● Expertise in Artificial Intelligence (AI), Machine Learning (ML), and Reduced
Order Modeling (ROM) for rapid thermal prediction, digital twins, and real-time
CFD surrogate modeling
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